Process Design & Detail Engineering - Certificate Program

Process Design Engineering is at the heart of much of the chemical, oil, gas, and petrochemical industries. The process design engineering deals with transportation and transformation of solids, liquids and gases in sync with other engineering disciplines including Mechanical, Electrical, Instrumentation etc. The other activities of specific importance are separation processes including distillation, heat transfer, hydraulics and fluid flow, reaction engineering, but also process control and economics. These are the fundamental principles of process engineering. This course considers the areas of process engineering that are most commonly encountered, and will provide a detail understanding of the fundamentals to the non-specialist, and a refresher to practicing engineers, with examples that will be drawn from a range of process industries including oil and gas processing, petrochemicals, chemical manufacturing.

Registration begins from : June 02, 2022

Process Design Course Agenda

Start your upskilling journey with our guided curriculum with application based learning approach.

Module 01 | Process Design Engineering - An Introduction

• Role of Process Engineer.

• Work flow chart in EPC.

• Process Design Deliverables.

• Basic Engineering Package 

• Front End Engineering Design.

• Engineering, Procurement & Commissioning.

• Upstream | Mid Stream | Down Stream.

Module 02 | Process Engineering Design Basis

• Process Engineering Design Basis.

• Design Pressure consideration in Process Design.

• Design Temperature consideration in Process Design.

• Material Selection for Process Conditions.

Module 03 | Process Simulations, Heat Mass Balance & Process Flow Diagram

• Simulators for Process Design.

• Components of a Process Simulator.

• Selection of Thermophysical Property Packages.

• Example of a Distillation Column Simulation.

Module 04 | Hydraulic Calculations in Process Design

• Line Sizing - Liquid | Gas | Two Phase.

• Pump Performance Curves.

• Pump Minimum Circulation Flow.

• Control Valves Sizing.

• Hydraulic Calculations for Pumping System

• Actual Problem Discussion.

• Compressible Flow & Flare Network Calculations.

Module 05 | Piping & Instrumentation Diagram - P&ID

• Process Engineering Design Basis.

• Design Pressure consideration in Process Design.

• Design Temperature consideration in Process Design.

• Material Selection for Process Conditions.

Module 06 | Pressure Safety Valve - PSV

• Terms: Set Pressure, Overpressure, Relieving Pressure, Blow-down, Reseating Pressure.

• Safety Valve, Relief valve v/s Safety Relief Valve.

• Conventional, Balanced Bellows & Pilot Type Safety Valve.

• Overpressure Scenarios, Allowable Overpressures and Sparing Philosophy.

• Calculations of Relief loads for Various Overpressure Scenarios.

• Orifice Sizing for Vapor, liquid and two phase relief.

Module 07 | Vessel Sizing

• Single Phase Vessel.

• Two Phase Separator Sizing.

• Three Phase Separator Sizing.

• Preparation of Excel Sheet.

Module 08 | Heat Exchanger Design

• Types of Heat Exchangers.

• TEMA Configurations.

• Design Parameters for Shell & Tube Heat Exchangers:

  • Exchanger Orientation.

  • Approach Temperatures.

  • Fouling Factors.

  • Fluid Allocation.

  • Baffle Orientation, Baffle Cut, Baffle Spacing.

• LMTD Correction factor, Shells in Series.

• Design example of a Heat Exchanger.

Module 09 | Distillation Column Design

• Mc-Cabe Thiele Method.

• Determination of Minimum no. of Stages, Minimum Reflux.

• Concept of Optimum Reflux.

• Determination of Actual no. of Stages at Optimum Reflux.

• Optimum Feed Tray Location, Reboiler & Condenser Duties.

• Tray Column v/s Packed Column.

• Tray Column Terminologies in Hydraulic Calculations.

• Operating/ Design Envelope for a Tray Column: Jet Flood, Downcomer Flood, Weeping, Entrainment.

• KG Tower Software for Hydraulic Calculations, Hydraulic Design Limits.

Module 10 | Compressor Study

• Types & Selection of Compressors.

• Centrifugal Compressor Performance Curves- Surge & Stone Wall Operation.

• Anti-Surge Control System.

• Compressor Capacity Control Methods.

• Settle-out Pressure Calculations.

• Typical Compressor P&ID Scheme.

• Multi-Stage Refrigeration System.

• Inter-Coolers in Multi-Stage Compressors.

Module 11 | Final Revision, Closing & Certification

• Doubts Clarifications.

• Typical Questions in a Process Engineering Interviews.

• Mock Interview Preparation.